Cutting member for a surgical instrument

ABSTRACT

A surgical instrument includes an end effector including a first jaw and a second jaw, a drive beam disposed inside the end effector, a first blade, and a second blade. The drive beam is slidably attached to the first jaw. The drive beam includes a cut-out defining a first surface, a second surface, and a vertical strut. The first blade is attached to the first surface and the vertical strut. The second blade is attached to the first blade and the second surface.

BACKGROUND Technical Field

This application relates to a surgical instrument, and more particularly, to surgical instruments which join and cut tissue.

Background of Related Art

Surgical instruments where tissue is first grasped or clamped between opposing jaw structures and then joined by surgical fasteners or RF energy are well known in the art. In some surgical instruments a knife is provided to cut the tissue which has been joined.

Typically, one of the members of the two opposing jaw structures is a staple cartridge which includes a tissue contacting surface and houses a plurality of staples arranged in at least two lateral or concentric rows while the other member is an anvil which includes an anvil plate as the tissue contacting surface and defines a surface for forming the staple legs as the staples are driven from the staple cartridge. A knife travels between the staple rows to cut and/or open the stapled tissue between the rows of staples.

Certain surgical procedures rely on the unique combination of clamping pressure, precise electrosurgical energy control (RF) and gap distance to seal or to cut tissue, vessels and certain vascular bundles. Instruments such as electrosurgical forceps are commonly used in open and endoscopic surgical procedures to coagulate, cauterize and seal tissue. Such forceps typically include a pair of jaw members that can be controlled by a surgeon to grasp targeted tissue, such as, e.g., a blood vessel. An example of an electrosurgical energy control instrument is disclosed, for example, in U.S. Patent Application No. 61/882,097 to Duffin et al., the entire contents of each of which are incorporated herein by reference.

In endoscopic or laparoscopic procedures, surgery is performed through a small incision or through a narrow cannula inserted through a small entrance wounds in the skin. In order to address the specific needs of endoscopic and/or laparoscopic surgical procedures, endoscopic surgical stapling instruments have been developed. Examples of endoscopic surgical stapling instruments are disclosed, for example, in U.S. Pat. No. 8,070,033 to Milliman et al. and U.S. Patent App. Pub. No. 2014/0103092 to Kostrzewski et al., the entire contents of each of which are incorporated herein by reference.

Varying the geometry and dimensions of the knife blade may improve the ability of the knife blade to slice through thick tissue.

SUMMARY

In accordance with the present disclosure, a surgical for joining and cutting tissue is provided. The surgical instrument includes an end effector having a proximal end and a distal end. The end effector includes a first jaw and a second jaw. The end effector further includes a drive beam that is slidably disposed in to the first jaw. The drive beam includes a cut-out defining a first surface, a second surface and a vertical strut. A first blade is attached to the first surface and the vertical strut and a second blade is attached to the first blade and the second surface.

In aspects, the first and second blades may be perpendicular to each other. In aspects, the first and second blades may have respective first and second blade edges that face one another. In aspects, each blade edge may be uniform or serrated. In other aspects, each blade edge may have serrations of a scalloped, wavy, pointed or saw toothed type. In aspects, the first jaw is an anvil assembly and the second jaw is a cartridge assembly.

In accordance with the present disclosure, an alternative embodiment of a surgical instrument is provided. The surgical instrument includes an end effector having a first jaw and a second jaw. The end effector further includes a drive beam slidably disposed in to the first jaw. The drive beam includes a cut-out defining a first surface, a second surface, and a vertical strut. A curved blade is attached to the first and second surfaces. The curved blade has a non-uniform radius of curvature.

In aspects, the curved blade may have a serrated blade edge. In aspects, the curved blade edge may be serrated of the scalloped, pointed, wavy or saw toothed type. In aspects, the curved blade may be concave relative to the drive beam. In other aspects, the curved blade may be convex relative to the drive beam.

In aspects, a proximal most portion of the curved blade may be biased toward the first jaw. In other aspects, a proximal most portion of the curved blade may be biased toward the second jaw. In aspects, the first jaw may be an anvil assembly and the second jaw may be a cartridge assembly.

In accordance with the present disclosure, an alternative embodiment of a surgical instrument is provided. The surgical instrument may include a stapling head assembly forming a tubular body portion defining a linear axis. The stapling head assembly may include a central support tube disposed within the stapling head assembly. An anvil assembly including an anvil head may be attached to an anvil shaft that is releasably connected to the central support tube of the stapling head assembly. A circular blade may be attached to the stapling head assembly. The circular blade may have a varying height about its circumference. In aspects, the circular blade may have a blade edge. In aspects, the blade edge may be serrated. In other aspects, the blade edge may be of the scalloped, wavy, pointed or saw toothed type.

Any of the above aspects of the present disclosure described may be combined with any other aspect of the present disclosure without departing from the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and, together with a general description of the disclosure given above and the detailed description of the embodiments given below, serve to explain the principles of the disclosure, wherein:

FIG. 1 is a perspective view of a linear surgical instrument according to the present disclosure;

FIG. 2 is a side cross-sectional view of the end effector of FIG. 1, taken along section line 2-2 of FIG. 1;

FIG. 3 is a perspective view of the drive bar assembly and knife assembly of the surgical stapler of FIG. 1;

FIG. 4A is a perspective view of the knife assembly of FIG. 3;

FIG. 4B is an alternative embodiment of the knife assembly of FIG. 4A;

FIG. 4C is a further embodiment of the knife assembly of FIG. 4A;

FIG. 5 is a perspective view of an annular surgical instrument according to the present disclosure;

FIG. 6 is a side cross-sectional view of the end effector of FIG. 5, taken along section line 6-6 of FIG. 5;

FIGS. 7A-7J are perspective views of knife blades for use with the surgical stapler of FIG. 5; and

FIG. 8 is a perspective view of an electrosurgical energy control instrument according to the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed surgical instrument will now be described in detail with reference to the drawings wherein like numerals designate identical or corresponding elements in each of the several views. As is common in the art, the term “proximal” refers to that part or component closer to the user or operator, while the term “distal” refers to that part or component farther away from the user.

FIG. 1 illustrates one embodiment of the presently disclosed surgical instrument apparatus shown generally as 100. Briefly, surgical instrument 100 generally includes a housing assembly 103 and an elongated body 104. The elongated body 104 includes an end effector 102 having a cartridge assembly 112 housing a plurality of surgical staples and an anvil assembly 122 pivotably coupled in relation to cartridge assembly 112. Detailed descriptions of examples of the functions of housing assembly 103 and end effector 102 are disclosed in U.S. Pat. No. 8,070,033 to Milliman et al. and U.S. Patent App. Pub. No. 2014/0103092 to Kostrzewski et al. already incorporated herein by reference.

Housing assembly 103 includes a movable handle member 105, a barrel portion 106 and a retraction member 107. Movable handle member 105 is operably coupled to end effector 102 such that upon actuation of movable handle member 105, end effector 102 is also actuated to grasp tissue, fire, and form fasteners through the grasped tissue. Actuation of handle may actuate a knife or cutting member located in the end effector that would cut tissue.

A retraction member 107 is movably positioned along barrel portion 106 and operatively associated with end effector 102. Retraction member 107 is actuatable to move end effector assembly 102 from an actuated or fired position to a released or pre fired position. During operation, as movable handle member 105 is actuated to fire surgical stapling instrument 100, retraction member 107 is translated distally. Although a manually operated handle assembly is shown, it is contemplated that the surgical instrument has a powered assembly such as one or more motors or that the end effector is a detachable component that can connect to a powered assembly, powered handle, robotic system, etc.

Referring to FIG. 2, end effector 102 includes a cartridge assembly 112, an anvil assembly 122, a drive bar assembly 130, and a knife assembly 140. The drive bar assembly 130 is disposed at least partially within proximal end of end effector 102 and in operative communication with housing assembly 103. It is configured such that actuation of handle assembly 105 causes drive bar assembly 130 and knife assembly 140 to translate distally through cartridge assembly 112 of end effector 102. As drive bar assembly 130 translates distally, it contacts staples 170, ejecting staples 170 from the cartridge assembly 112 and through tissue disposed between the cartridge and anvil plates 113, 123.

Referring to FIGS. 2 and 3, drive bar assembly 130 is elongate in shape and includes knife assembly 140 attached to the distal end thereof. Knife assembly 140 defines a substantially I-shaped cross section having a top flange 142, a bottom flange 144, and a cut-out 146. Top flange 142 of knife assembly 140 is configured to translate through an interior slot 124 of anvil assembly 122 while bottom flange 144 is configured to translate longitudinally along an underside 119 of cartridge assembly 112. Cut-out 146 is open on the distal most portion of knife assembly 140 and extends proximally therein, defining a first surface 146 a, a strut 146 b, and a second surface 146 c. Cut-out 146 resembles a “C” shape formed in knife assembly 140.

Referring to FIGS. 3 and 4A, knife assembly 140 further includes a knife blade 150 disposed within cut-out 146. Knife blade 150 has a first blade 152 and a second blade 154. First and second blades 152, 154 each are shown in this illustrative embodiment as having a straight edge 156, however, it is contemplated that first and second blades 152, 154 may have a serrated edge. First blade 152 is attached to the distal end of first surface 146 a and vertical strut 146 b thereby creating an angled orientation relative to vertical strut 146 b. Second blade 154 is attached to first blade 152 and extends between first blade 152 and the distal end of second surface 146 c, positioning second blade at a 90 degree angle relative to first blade 152. The positioning of first and second blades 152, 154 create a “V” shape that opens towards the distal end or firing direction. Although second blade 154 is attached near one end of first blade 152, it is contemplated that second blade 154 may be attached anywhere along first blade 152, whereby each attachment point defines a different angle between the first and second blades 152, 154.

Referring to FIGS. 4A-4C, three embodiments of knife assemblies 140, 240, and 340 are shown. It is contemplated that one of knife assemblies 140, 240, and 340 is used with surgical stapler 100, where a specific knife assembly is provided in cartridge assembly 112. Each cartridge assembly 112 may include one of knife assemblies 140, 240, or 340 and the user may select a cartridge assembly 112 having a desired knife assembly. As previously discussed, FIG. 4A shows a knife assembly having a top flange 142, a bottom flange 144, a cut-out 146 and a knife blade 150 disposed within cut-out 146.

Shown in FIG. 4B is knife assembly 240 defining a substantially I-shaped cross section having a top flange 242 a bottom flange 244, and a cut-out 246. Top flange 242 of knife assembly 240 is configured to translate through an interior slot 124 of anvil assembly 122 while bottom flange 244 is configured to translate longitudinally along an underside 119 of cartridge assembly 112. Cut-out 246 is open on the distal most portion of knife assembly 240 and extends proximally therein, defining a first surface 246 a, a strut 246 b, and a second surface 246 c. Knife assembly 240 further includes a knife blade 250 disposed within cut-out 246.

Knife blade 250 is curved, having a sharp, arcuate edge 256. Although knife blade 250 is shown having a sharp, arcuate edge, it may have any suitable edge including a serrated edge. Furthermore, the serrated edge may have serrations of the scalloped 650 (FIG. 7C), wavy 860 (FIG. 7E) and 950 (FIG. 7F) or saw toothed 550 (FIG. 7B), 750 (FIG. 7D) and 1050 (FIG. 7G) type. Knife blade 250 may define a parabola having a first end 250 a, a vertex 250 b, and a second end 250 c. First and second ends 250 a, 250 c of knife blade 250 are attached to the respective first and second surfaces 246 a, 246 c of cut-out 246. Vertex 250 b of knife blade 250 is located substantially in the middle of knife blade 250 and disposed proximal of first and seconds ends 250 a, 250 c of knife blade 250. This configuration of knife blade 250 creates a “C” shape that opens towards the distal end or firing direction. Although vertex 250 b of knife blade 250 is shown in the illustrative embodiment of FIG. 4B as located substantially in the middle of knife blade 250, it is contemplated that vertex 250 b may be located anywhere along knife blade 250, biasing vertex 250 b toward the cartridge or anvil plates 113, 123, thereby changing the curvature of knife blade 250.

Shown in FIG. 4C is another knife blade 340 in accordance with an embodiment of the present disclosure. Knife blade 340 is substantially similar to knife blade 240 (FIG. 4B), with similar elements represented by similar numerals. As such only the differences are discussed in detail below.

First and second ends 350 a, 350 c of knife blade 350 are attached to the respective first and second surfaces 346 a, 346 c. Vertex 350 b of knife blade 350 may be located substantially in the middle of knife blade 350 and disposed distal of first and seconds ends 350 a, 350 c of knife blade 350. This convex configuration creates a reverse “C” shape that faces toward the proximal end or away from the firing direction. Although the vertex 350 b of knife blade 350 is located substantially in the middle of knife blade 350 in the illustrative embodiment shown in FIG. 4C, it is contemplated that vertex 350 b may be located anywhere along knife blade 350, biasing vertex 350 b toward the cartridge or anvil plates 113, 123, thereby changing the curvature of knife blade 350.

Shown in FIGS. 5 and 6, is an annular surgical stapling instrument generally designated as 400. Surgical stapling instrument 400 includes a handle assembly 403 having at least one pivotable actuating handle member 405 and an advancing member 407. Extending from handle member 405, is a tubular body portion 404 which may be constructed so as to have a curved shape along its length. Body portion 400 terminates at an end effector 402.

End effector 402 includes a staple cartridge assembly 412 defining an inner wall 414 and an outer wall 416. Inner wall 414 forms an opening 414 a in the distal end of staple cartridge assembly 412. Tubular body portion 404 includes a central shaft 412 a extending through opening 414 a of staple cartridge assembly 412. Staple cartridge assembly 412 further includes at least one annular array of staples (not shown) disposed in each of the staple receiving slots 418. Staple receiving slots 418 extend through a tissue contacting surface 420 of the distal end of the staple cartridge assembly 412.

Staple cartridge assembly 412 may be fixedly connected to the distal end of tubular body portion 404 or may be configured to concentrically fit within the distal end of tubular body portion 404. Typically, staple cartridge assembly 412 includes a staple pusher 428 and a knife 450, substantially in the form of an open cup with the rim thereof defining a knife edge 456, disposed within staple cartridge assembly 412. Staple pusher 428 assists on ejecting the staples 170 from the cartridge assembly 112. The knife edge 456 is disposed radially inward of the staple receiving slots 418. Staples 170 and ejects staples 170 from the cartridge assembly 112

End effector 402 further includes an anvil assembly 422 positioned distally of staple cartridge assembly 412. Anvil assembly 422 has an anvil member 424 and a shaft 426 removably connected to the central shaft 412 a of staple cartridge assembly 412.

Reference may be made to U.S. Pat. No. 5,915,616 to Viola et al., the entire contents of which are incorporated herein by reference, for a detailed discussion of the construction and operation of an illustrative annular stapling instrument.

Turning now to FIG. 7A, knife 450 is shown having a uniform cutting knife edge 456. In operation, a portion of knife 450 is urged from the staple cartridge assembly 412 and knife edge 456 severs tissue grasped between staple cartridge assembly 412 and anvil assembly 422.

With reference to FIGS. 7B-7I, shown are various exemplary embodiments of knife blade profiles that may be used in surgical stapler 400. Knife blades 550, 650, 750, 850, 950, 1050, 1150, 1250 shown in FIGS. 7B-7I are configured such that any of these knife blades could be used with surgical stapler 400. As shown in FIGS. 7B-7J, knife blades 550, 650, 750, 850, may have a serrated, or have any other suitable knife edge pattern. Additionally knife blades of FIG. 7A-7I are shown in a circular shape but are not limited to a uniform radius of curvature, or a uniform height. Additionally, FIGS. 7B, 7D, 7G, and 7H depict saw toothed blades. FIG. 7H has a non-uniform height. With respect to FIG. 7C, a scalloped blade is presented. With respect to FIGS. 7E and 7F, blades of the wavy type are shown with blade 950 having a non-uniform height. With additional reference to FIGS. 7A-7I, knife blades 450-1250 may have a varying height about the circumference.

Adding compound angles, one or more leading edge(s), or other distinct features that cut tissue from various angles or in a progressive manner improves the ability of knife blades 550, 650, 750, 850, 950, 1050, 1150, 1250 to slice through thick tissue by reducing the area of the blade that initially contacts the tissue, which would more easily initiate and propagate tissue transection.

Referring now to FIG. 8, is an electrosurgical energy control instrument generally designated as 500. Electrosurgical energy control instrument 500 generally includes a housing 512 that supports various actuators thereon for remotely controlling an end effector 514 through an elongated shaft 516. To mechanically control the end effector 514, the housing 512 supports a stationary handle 520, a movable handle 522, a trigger 526 and a rotation knob 528. The movable handle 522 is operable to move the end effector 514 between an open configuration wherein a pair of opposed jaw members 530, 532 are disposed in spaced relation relative to one another, and a closed or clamping configuration wherein the jaw members 530, 532 are closer together. Approximation of the movable handle 522 with the stationary handle 520 serves to move the end effector 514 to the closed configuration and separation of the movable handle 522 from the stationary handle 520 serves to move the end effector 514 to the open configuration.

When in use, the end effector 514 of the electrosurgical energy control instrument may be moved from an open configuration wherein tissue (not shown) is received between the jaw members 530, 532, and a closed configuration, wherein the tissue is clamped and treated. The jaw members 530, 532 pivot about a pivot pin 544 to move the end effector 514 to the closed configuration wherein a sealing plate 548 and a sealing plate 551 provide a pressure to tissue grasped there between. Additionally, the upper and lower jaw member 530 and 532 can be configured to provide a pathway to drive a knife assembly (FIGS. 4A-4B) having a similar configuration as seen in FIG. 2. Furthermore, a connection of the movable handle 522 and the knife trigger 526 to the longitudinally movable components of the elongated shaft 516 is described. The movable handle 522 may be manipulated to impart longitudinal motion to the outer shaft member 560, and the knife trigger 526 may be manipulated to impart longitudinal motion to the knife rod 502 (not shown). As discussed above, longitudinal motion of the outer shaft member 560 serves to move the end effector 514 between the open configuration and the closed configuration, and longitudinal motion of the knife rod 502 (not shown) serves to move a knife blade through knife channel 558 (not shown) similar as described in FIG. 1.A.

In some embodiments, the sealing plates 548 and 551 are electrically coupled to opposite terminals, e.g., positive or active (+) and negative or return (−) terminals associated with a generator 541. Thus, bipolar energy may be provided through the sealing plates 548 and 551 to tissue. Alternatively, the sealing plates 548 and 551 may be configured to deliver monopolar energy to tissue. In a monopolar configuration, one or both sealing plates 548 and 551 deliver electrosurgical energy from an active terminal, e.g., (+), while a return pad (not shown) is placed generally on a patient and provides a return path to the opposite terminal, e.g., (−), of the generator 541. More detailed discussion of electrosurgical energy control instrument 500 can be found in U.S. Patent Application No. 61/882,097 to Duffin et al., filed on Sep. 25, 2013 and entitled “Wire Retention Unit for Surgical Instrument,” the entire contents of which has being incorporated herein by reference.

It is contemplated that individual features of the above described embodiments may be combined without departing from the scope of the present disclosure.

Although the illustrative embodiments of the present disclosure have been described herein with reference to the accompanying drawings, the above description, disclosure, and figures should not be construed as limiting, but merely as exemplifications of particular embodiments. It is to be understood, therefore, that the disclosure is not limited to the precise embodiments described herein, and that various other changes and modifications may be effected by one skilled in the art without departing from the scope or spirit of the present disclosure. 

What is claimed is:
 1. A surgical instrument, comprising: an end effector having a proximal end and a distal end, the end effector including a first jaw and a second jaw; a drive beam disposed inside the end effector and slidably attached to the first jaw, the drive beam includes a cut-out defining a first surface, a second surface, and a vertical strut, the first and second surfaces opposing each other; a first blade attached to the vertical strut and including a first cutting edge extending linearly from the first surface to the second surface such that the first cutting edge defines an acute angle with respect to the vertical strut; and a second blade attached to the first blade and the second surface such that the second blade is in contact with the first cutting edge of the first blade.
 2. The surgical instrument of claim 1, wherein a portion of the first cutting edge of the first blade is perpendicular to an edge of the second blade.
 3. The surgical instrument of claim 1, wherein the second blade has a second cutting edge oriented towards the first cutting edge of the first blade.
 4. The surgical instrument of claim 3, wherein at least one of the first or second cutting edges are serrated.
 5. The surgical instrument of claim 3, wherein at least one of the first or second cutting edges are uniform.
 6. The surgical instrument of claim 1, wherein the first jaw is an anvil assembly and the second jaw is a cartridge assembly.
 7. The surgical instrument of claim 1, wherein the first and second blades are formed of separate components.
 8. The surgical instrument of claim 1, wherein at least a portion of the second blade is interposed between the first blade and the second surface. 